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A fossil fuel Consists of several fractions A mixture of very wide range of Hydrocarbons Normally Black in color Available in plenty in Middle East (Persian Gulf) Also available in North & western Africa, Indonesia, South & Central America, Scandinavia In India, it is available in Bombay High, KrishnaGodhavari basin, Assam & Rajastan
What is a Refinery?
A refinery is a complex integration of several process units that work in a coordinated fashion to make customized fuels and valuable petrochemical feed stocks. It includes Blending.
Crude Dist Unit & Vac Dist Unit Hydro treating unit Fluid Catalytic Cracking unit Delayed Coker unit Merox Sulfur Rec.Unit & ATU Refinery Tank Farm
RRT
RRT
RTF
S F Cr 1 M H Cr 2 A ETP
U C A
CPP
PP
Material Flow
SPM 2 Nos.
Jetties 4 Nos.
MTF
RTF
Pipeline despatch
Road loading Rail loading RRTF
Reliance
L & l l ma
BPCL
& e g ar
x e l p m Co
Si
le p m
S
Bongaigon Digboi Haldia Vizag
HPCL
MRL
Capacity
Source: Chemsystem
251 OX-FR
271/272/273 ISOMAR
HN
LPG
GAS OIL
DIESEL ETHYLENE
PP PROPYLENE MS
311/312 VDU
411/412/413 FCC
180-215
LCO
180-215 GT FUEL
C5
TAME CSO
RFG CSO
431 ARU
SULFUR COKE
The objective of the Unit is to separate the crude oil into various fractions viz: Off gases or Lean gases Liquefied Petroleum Gas (LPG) Full Range Naphtha (FRN) Light Kerosene (LK) Heavy Kerosene (HK) Diesel (AGO or HSD) Gas Oils (HAGO / LVGO / HVGO) Vacuum Residue (VR)
CDU Process
Other stream s from D H T, VGOH T, LN U U ,H N U U
Lean Gas
S G C
LP G
FR N
LK / ATF
Old Desalters
C rude In
1st Stg.
2nd Stg.
1st Stg.
2nd Stg.
Flash Drun
Preheat 2
Heater
H K
D iesel
Preheat 1
New Desalters
Preheat 3
H AGO
LVGO
Water In
Heater
Brine Out
V a c. C o l.
H VGO
VacuumR esidue
Major Equipment
Desalters Fired Heaters Heat Integration circuit Crude Flash Drum Main Fractionator Side strippers Multi Stage Ejector system
Why FCC ?
Heavier Crudes Need for cracking heavy ends Heavy demand for lighter fuels
Why FCC
Converts VGO in to Gasoline and lighter products. Cheapest available conversion process Offers great flexibility of operation (can be run in LPG, Gasoline or distillate mode) Produces large quantity of Petrochemical feed stocks
Major Equipment
Reactor and Regenerator Power recovery trains (PRTs) Vortex separators/ Cyclones Main Air Blower/Expander/Motor generators/Steam generator Flue gas cooler Main Fractionator/ Side Stripper Waste Heat Boiler
Hp Receiver Stripper Debutanizer, C3C4 splitter Absorber Amine absorber Naphtha splitter Depentanizer
To separate Close boiling range lighter products like Fuel gas, LPG, Gasoline, Naptha. Acts as partial heat sink for Main fractionator. Stabilizes Naptha H2S removal from gaseous products.
A Hydro treater/ Union finer is a process unit Where Hydrocarbon Feed is treated with hydrogen in presence of catalyst at high temperature & pressure. Desulfurization(3.2wt% 0.2wt%) 94% Denitrification (1658 ppm 760ppm) Aromatic and Olefin saturation
DIESEL HYDROTREATER
DHT
Major Equipments
Recycle Gas Compressor Fixed Bed Catalytic Reactor Catalyst 300m3 (NiMo CoMo) Fired Heater Stripper
A
NA PHTHA PR E HEA T EX FEED DIES EL S TRIPPER
FILTER
FUR NA CE
R EA CTOR
Fi N COOLER
D r i e r
Lo w mo isture DIES EL PROD UCT
VGO HYDROTREATER
VGOHT
A
NAPHTHA PRE HEAT EX FEED VGO FILTER FURNACE FRACTIONATOR REACTOR
Kerosene
DIESEL
FAN COOLER
Why VGOHT ?
The Gas Oil product ex. Crude/Coker has high sulfur content. This is to be reduced before sending to FCC for SOX emission control Hydro-desulphurization of Gas oil is carried out in VGO hydro treating units. De Nitrification of Gas oil
Recycle Gas Compressor Fixed Bed Catalytic Reactor Catalyst 300m3 (NiMo CoMo) Fired Heater Stripper
Sulfur Complex
Sour Water Stripping Unit (SWS) Amine Treating Unit (ATU) Sulfur Recovery Unit (SRU)CBA Granulation Unit
Granulation Unit
S -Dispatch
SRU Objective
Main Objective of the unit is to convert H2S in to elemental Sulfur.
Why SRU ?
More Stringent environmental norms of Government / regulatory bodies. Enables the refinery to process High sulfur crudes.
SRU Process
Acid gas from SWS and ATU stripper is oxidized (burnt) in 2 stages and then treated in catalytic converter. The molten sulfur is transferred to SGU to form Sulfur granules.
Major Equipment
Amine absorber Flash drum Stripper Reaction furnace Catalytic Reactor Incinerator Waste heat boiler
Acid Gas
FG In
Flash Drum
RA Pump
LA Pump
Lean Amine
CBA-Equipment
Claus Reactor Reaction Furnace
V03
LPG C.A
CBA Reactors
R02 R03
Steam Drum
R01
WHB
F02
Acid Gas
B01
B02
S03 S04 S05 S06
Steam Drum
V04
Stack
F03
WHB
Sulphur, max. Benzene, max. RON, min MON, min AKI, min Aromatics, max. Olefins, max. E 70 E 100
@ The Benzene content will be progressively reduced to 1 vol% by Apr 2005 in 7 mega cities. The rest of the country would have a maximum limit of 3 vol% from Apr 2005. # 50 ppmw to be supplied from 2005 & 10 ppmw by 2008 ** to be reviewed by 2005 by European Union.
@ Cetane number 48 or Cetane index 46 # 50 ppmw to be supplied from 2005 & 10 ppmw by 2008 ** to be reviewed by 2005 by European Union.
Sulfur in Diesel to go down to 50 ppm by 2010 and Cetane Number will be above 51
A thermal cracking and successive polymerization process-rapid heating of vacuum residue ( ex VDU) above cracking temperature to form mixture of distillates and coke. The process of formation of coke is delayed in the furnace by way of maintaining higher velocities using HP steam/ BFW
Why DCU ?
High margin No Fuel oil generation Value added products (LPG, Diesel, Naphtha, Fuel gas and Coke) No Catalyst Involved Capable of processing Refinery slop and sludge
Coke drum Fractionator Fired Heater Blow down system Coke Cutting system- PLC based Heat Integration circuit Heading and De heading unit Product Filter-PLC based
RTF Overview
Functions of RTF
Ensure uninterrupted supply of Crude Oil and other feed/intermediates to Various Units. Receive intermediates, products and blending components from various units. Supply of RFO & slop for reprocessing. Blending Correction of Offspec product.
FINAL PRODUCTS
AROMATIC COMPLEX
FUEL COMPONENTS
HEAVY NAPHTHA
INTERMEDITE PRODUCT STORAGE
MTF
FINAL PRODUCTS STORAGE
INTERMEDIATE PRODUCTS
FINAL PRODUCTS
BLEND COMPONENTS STORAGE
RFO
REFINERY COMPLEX
BLEND HEADER
RAW MATERIALS
RAW MATERIALS STORAGE
RAW MATERIALS
RRTF
SLOPS
SLOPS STORAGE
RTF
Major Equipment
Fixed Roof Storage tanks Floating roof Storage Tanks Horton Spheres Mixers Pumps
Any Questions ?
Thank you